Major production expansion without disruption to ongoing operations
Market
Heavy Industrial
Key Services
Construction
Preconstruction
Self-Perform
Strategic Partnerships
Delivery Method
General Contracting (GC)Self Perform %
76Capacity
7,000 tons per dayThe challenge
The 7,000-ton-per-day expansion of Buzzi Unicem USA’s Festus cement plant posed multifaceted challenges. Replacing parts of an existing 40-year-old plant with an innovative preheater pyrotechnology system that allows for more environmentally friendly and cost-effective cement production required meticulous coordination and precise installation. Completing this complex project within a critical 24-month timeline while ensuring continuous production operations on this congested site added a layer of intricacy.
Key Facts
7,000-tons-per-day expansion
150-ton equipment modules
76% self-perform
Challenge met
As the general contractor, we confronted these challenges with strategic expertise. Collaborating closely with Buzzi and the design team, we orchestrated equipment vendors, eliminating fit-up issues. Our seasoned workforce handled the intricate process equipment installation, including the hefty 550-ton-per-hour roller raw mill, 190-ton-per-hour vertical roller finish mill, and a 400-foot-tall cyclone preheater tower.
Leveraging our inland waterways experience, Alberici capitalized on cost and schedule efficiencies. By employing our marine equipment fleet and the plant’s river terminal, material deliveries were streamlined, and workspace was optimized. Erecting a substantial ringer crane on the shore facilitated efficient barge equipment delivery, ensuring project adherence to the demanding schedule. The successful outcome underlines our prowess in executing intricate industrial expansions seamlessly.
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